Sensor and tooth arrangement for shaft speed detection

ABSTRACT

A non-ferrous shaft includes multiple non-integral ferrous tooth components, thereby allowing a sensor to detect the shaft speed.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.13/607,986 filed Sep. 10, 2012 and is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to turbine engine shafts, andmore particularly to a sensor arrangement for detecting a rotationalspeed of a shaft.

BACKGROUND OF THE INVENTION

Fan based turbine engines, such as those utilized on commercialaircraft, include a fan/compressor connected to turbine sections of theturbine engine via a low shaft. The turbine sections cause the low shaftto rotate, which in turn causes the fan/compressor to rotate and drawsair into the fan based turbine engine. In order to control the speed ofthe fan/compressor, and thereby control airflow through the turbineengine, a magnetic fan shaft speed sensor is utilized in conjunctionwith a controller. The magnetic low shaft speed sensor monitors therotational speed of the low shaft and the controller makes correspondingadjustments to control the low shaft speed based on the monitored speed.

In a typical arrangement, the low shaft includes multiple sensor teeththat extend radially out from the low shaft. The teeth are arrangedcircumferentially around the main shaft body. The teeth and the shaftare an integral monolithic component. A magnetic sensor is locatedadjacent to the shaft, aligned with the sensor teeth, and detects eachsensor tooth as the sensor tooth rotates through the magnetic fieldgenerated by the magnetic sensor. The sensor is preloaded with thenumber of sensor teeth on the shaft and determines that one fullrotation of the shaft has occurred when the preloaded number of sensorteeth has been detected. Using this arrangement, the speed of the shaftcan be determined by the magnetic shaft speed sensor according toconventional techniques.

Due to the inherent sensing capabilities of the magnetic shaft speedsensor, the shaft in this arrangement is required to be constructed of aferrous material, such as steel, or the magnetic sensor will be unableto detect the teeth. A steel shaft is inherently heavier that alternate,non-ferrous, shaft materials, such as titanium alloy.

SUMMARY OF THE INVENTION

A turbine engine according to an exemplary embodiment of thisdisclosure, among other possible things includes a non-ferrous shaft, aplurality of ferrous tooth components arranged circumferentially aboutthe shaft, and a sensor operable to detect each of the plurality offerrous tooth components rotating past the sensor and thereby detect arotational speed of said shaft.

In a further embodiment of the foregoing turbine engine, each of theplurality of ferrous tooth components comprises, a base portioncontacting an inner diameter surface of the shaft, a load bearingportion extending radially outward from the base portion relative to anaxis defined by the shaft, a tooth portion extending radially outwardfrom the load bearing portion relative to the axis defined by the shaft.

In a further embodiment of the foregoing turbine engine, each of thebase portions is connected to shaft via a plurality of fasteners.

In a further embodiment of the foregoing turbine engine, each of theload bearing portions extends into a solid portion of the shaft suchthat an outer diameter surface of the load bearing portion isapproximately flush with an outer diameter surface of the shaft.

In a further embodiment of the foregoing turbine engine, each of theload bearing portions is shaped to fit in a corresponding shaft slot.

In a further embodiment of the foregoing turbine engine, each of thetooth portions extends radially outward from the load bearing portionsuch that the tooth portion is at least partially exterior to the shaft.

In a further embodiment of the foregoing turbine engine, each of thetooth portions is entirely exterior to the shaft.

In a further embodiment of the foregoing turbine engine, the toothportion is angled relative to the shaft axis such that tooth portion isvertical relative to the sensor.

In a further embodiment of the foregoing turbine engine, the sensor is amagnetic shaft speed sensor.

In a further embodiment of the foregoing turbine engine, each of theplurality of ferrous tooth components is at least partially constructedof steel.

In a further embodiment of the foregoing turbine engine, the non-ferrousshaft is constructed of a material selected from the list of nickel,titanium, and aluminum.

In a further embodiment of the foregoing turbine engine, the pluralityof ferrous tooth components comprise at least two groups of toothcomponents and wherein the first group of tooth components has a firstdegree of magnetism and the second group of tooth components has asecond degree of magnetism distinguishable from the first degree ofmagnetism.

A ferrous tooth component for a shaft according to an exemplaryembodiment of this disclosure, among other possible things includes abase portion, a load bearing portion extending outward from the baseportion, and a tooth portion extending outward from the load bearingportion.

In a further embodiment of the ferrous tooth, the base portion comprisesa curved contact surface, wherein a contour of the curved contactsurface is such that the curved contact surface is flush with an innerdiameter of a shaft in an installed position.

In a further embodiment of the ferrous tooth, the base portion comprisesa plurality of fastener holes.

In a further embodiment of the ferrous tooth, the load bearing portionextends from the base portion such that an outer diameter surface of theload bearing portion is approximately flush with an outer diametersurface of a shaft when the ferrous tooth is in an installed position.

In a further embodiment of the ferrous tooth, each of the load bearingportions is shaped to fit in a corresponding shaft slot.

In a further embodiment of the ferrous tooth, each of the load bearingportions is keyed.

In a further embodiment of the ferrous tooth, each of the tooth portionsextends radially outward from the load bearing portion such that thetooth portion is at least partially exterior to a shaft in an installedposition.

In a further embodiment of the ferrous tooth, the tooth portion isangled relative to the contact surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a highly schematic fan based turbine engine.

FIG. 2A illustrates a top view of a ferrous tooth component for anon-ferrous fan shaft.

FIG. 2B illustrates a side view of a ferrous tooth component for anon-ferrous fan shaft.

FIG. 2C illustrates a front view of a ferrous tooth component for anon-ferrous fan shaft.

FIG. 3 illustrates a schematic sectional view of a portion of a fanshaft for a fan based turbine engine.

DETAILED DESCRIPTION

FIG. 1 illustrates a highly schematic fan based turbine engine 10. Theturbine engine 10 includes a fan/compressor 20, connected to a turbinesection 30 of the turbine engine 10 via a low shaft 40. The turbineengine 10 includes a magnetic shaft speed sensor 50. Multiple toothcomponents 42 are arranged circumferentially about the shaft 40 adjacentto the shaft speed sensor 50. As the shaft 40 rotates, the toothcomponents 42 rotate through a magnetic field output by the magneticshaft speed sensor 50. Each of the tooth components 42 is ferrous andinteracts with the field emitted by the magnetic shaft speed sensor 50.The magnetic shaft speed sensor 50 detects this interactivity, andthereby detects the tooth component 42 passing the sensor 50. Once apredetermined number of tooth components 42 are detected, the speedsensor determines that a full rotation of the shaft 40 has occurred, andthe rotational speed of the shaft 40 is determined based on the timeelapsed during a full rotation. In one example multiple types of toothcomponents 42 are used, with each type having a different degree ofmagnetism. The example arrangement allows for a once per revolutionsignal to be detected, or enables a specific clocking orientation of therotor.

The low shaft 40 is constructed of a non-ferrous material, such astitanium or titanium alloy, and the tooth components 42 are constructedof a ferrous material such as steel. For the purposes of this disclosure“ferrous” refers to any material that interacts with a magnetic fieldand “non-ferrous” refers to any material that does not interact with amagnetic field. Utilization of separate, ferrous, tooth components 42allows a non-ferrous fan shaft 40 to be utilized in conjunction with amagnetic fan shaft sensor 50.

The tooth components 42 are arranged circumferentially around the shaft40 with each tooth component 42 being approximately equidistant fromeach adjacent tooth component 42. By evenly spacing the tooth components42 around the shaft 40, the speed measurements from the magnetic shaftspeed sensor 50 can be acquired incrementally, rather than requiring afull rotation of the fan shaft 40. Minor variation in the distancebetween adjacent tooth components 42 is the result of manufacturing andassembly tolerances. The even circumferential distribution of the toothcomponents 42, further ensures that the shaft 40 remains balanced duringoperation.

FIGS. 2A, 2B, and 2C illustrate a top view (FIG. 2A), a side view (FIG.2B) and a front view (FIG. 2C) of a tooth component 100 that can be usedin the turbine engine 10 arrangement illustrated in FIG. 1. In theillustrated example, the tooth component 100 includes a base portion 110with multiple fastener holes 112. The base portion 110 includes acontact surface 114 that contacts an inner diameter surface of the fanshaft 40 (illustrated in FIG. 1) when the tooth component 100 isinstalled. The illustrated contact surface 114 is a rectangular surfacewith rounded corners, however, any geometric shape with room for both aload bearing portion and can be utilized for the contact surface 114.Protruding from the contact surface 114 of the base portion 110 is aload bearing portion 120. The load bearing portion 120 has a greaterdepth (length normal to the contact surface 114 of the base portion 110)than the base portion 110, and is shaped to fit a corresponding slot inthe fan shaft 40. In alternate examples the tooth component 100 isconnected to the turbine engine 10 using a different connection andfastener holes 112 are not required.

Each of the tooth components 100 also includes a tooth portion 130 thatextends from the load bearing portion 120. In an installedconfiguration, the tooth portion 130 extends radially outward from theshaft beyond an outer diameter surface of the shaft. The tooth portion130 is angled relative to a line normal to the contact surface 114 ofthe base portion 110. The particular angle of the tooth portion 130 isbased on the location and angle of the corresponding magnetic shaftspeed sensor 50 in an installed configuration.

While illustrated as a level planar surface in FIGS. 2A, 2B, and 2C fordescriptive effect, in a practical implementation, the contact surface114 of the base portion 110 is curved to match an interior diametersurface curve of the fan shaft 40. The matching curved surface allowsthe contact surface 114 of the base portion 110 to be flush with theinner diameter surface of the shaft, thereby minimizing vibrational wearand tear.

FIG. 3 illustrates a schematic sectional view of a portion of a shaft200, including multiple tooth components 210 located inside the shaft200 and extending out of the shaft 200. As described with regards toFIGS. 2A, 2B, and 2C, each of the tooth components 210 has a baseportion 212, a load bearing portion 214, and a tooth portion 216. Thebase portions 212 include fastener holes 218. In the illustratedinstalled position, the fastener holes 218 in the base portion 212 ofeach tooth component 210 line up with corresponding fastener holes 220in the shaft 200. A fastener (not pictured) protrudes through both thefastener hole 218 in the base portion 212 and the corresponding fastenerhole 220 in the shaft 200, thereby holding the tooth component 210 inplace. In one example, a rivet style fastener is used. Alternately,other known fastener types may be used.

A magnetic speed sensor 230 is positioned adjacent to the shaft 200 anddetects each tooth portion 216 as the tooth portion 216 rotates throughthe magnetic field generated by the magnetic sensor 230. The illustratedmagnetic sensor 230 is angled due to turbine engine design constraints.The angle of the tooth portion 216 aligns the ferrous tooth of the toothcomponent 210 with the magnetic sensor 230 such that the tooth portion216 appears vertical relative to the magnetic sensor 230. Aligning theferrous tooth vertically relative to the magnetic sensor 230 optimizesthe ability of the magnetic sensor 230 to detect a tooth component 210rotating through the magnetic field generated by the magnetic sensor230.

The shaft 200 further includes a slot 250 shaped to fit the load bearingportion 214 of the tooth component 210. When installed, the load bearingportion 214 of the tooth component 210 extends into the shaft 200 in thecorresponding slot 250 and supports twisting loads placed on the toothcomponent 210. By fitting the load bearing portion 214 of the toothcomponent 210 to the fan shaft slot 250, the rotational forces of therotating shaft 200 are applied to the load bearing portion 214 and thebase portion 212 of the tooth component 210 instead of being applied tothe fasteners in the fastener holes 220, 218.

The load placed on the fasteners is further reduced by placing the toothcomponent 210 inside the shaft 200 rather than on an outer diametersurface of the shaft 200. By placing the tooth component 210 inside theshaft 200, centripetal force pushes the tooth component 210 against theshaft, thereby reducing the load on the fasteners. If, instead, thetooth component 200 were external to the shaft 200, centripetal forcewould push the tooth component 200 radially away from the shaft, therebyincreasing the load on the fasteners.

The illustrated example tooth component 210 load bearing portion 214extends the full radial length of the shaft 200 and is flush with theouter diameter surface of the fan shaft 200. It is understood, however,that alternate examples can include a load bearing portion 214 thatextends only partially into the shaft 200. In such an arrangement, thecorresponding shaped fitted slot 250 on the fan shaft 200 is similarlyshaped. In one alternate example the shaft slot 250 is a keyed slot,thereby prevented incorrect orientation of the tooth component 210during assembly.

Although an embodiment of this invention has been disclosed, a worker ofordinary skill in this art would recognize that certain modificationswould come within the scope of this invention. For that reason, thefollowing claims should be studied to determine the true scope andcontent of this invention.

1. A ferrous tooth component for a turbine engine shaft comprising: abase portion configured to contact an inner surface of a shaft when theferrous tooth component is in an installed position; a load bearingportion extending radially outward from said base portion, relative to ashaft; and a tooth portion extending radially outward from said loadbearing portion, relative to the shaft.
 2. The ferrous tooth componentof claim 1, wherein said base portion comprises a curved contactsurface, wherein a contour of said curved contact surface is such thatsaid curved contact surface is flush with an inner diameter of the shaftin an installed position.
 3. The ferrous tooth of claim 1, wherein saidbase portion comprises a plurality of fastener holes.
 4. The ferroustooth of claim 1, wherein said load bearing portion extends from saidbase portion such that an outer diameter surface of the load bearingportion is approximately flush with an outer diameter surface of theshaft when the ferrous tooth is in an installed position.
 5. The ferroustooth of claim 3, wherein said load bearing portion is shaped to fit ina corresponding shaft slot.
 6. The ferrous tooth of claim 4, whereinsaid load bearing portion is keyed.
 7. The ferrous tooth of claim 1,wherein said tooth portion extends radially outward from said loadbearing portion such that said tooth portion is at least partiallyexterior to the shaft in an installed position.
 8. The ferrous tooth ofclaim 1, wherein said tooth portion is angled relative to said contactsurface.
 9. A turbine engine comprising; a non-ferrous shaft; aplurality of ferrous tooth components arranged circumferentially aboutsaid shaft, each of said ferrous tooth components being a separatephysical component from each other of said ferrous tooth components; anda sensor operable to detect each of said plurality of ferrous toothcomponents rotating past said sensor and thereby detect a rotationalspeed of said shaft.
 10. The turbine engine of claim 9, wherein saidsensor is a magnetic shaft speed sensor.
 11. The turbine engine of claim9, wherein each of said plurality of ferrous tooth components is atleast partially constructed of steel.
 12. The turbine engine of claim 9,wherein said non-ferrous shaft is constructed of a material selectedfrom the list of nickel, titanium, and aluminum.
 13. The turbine engineof claim 9, wherein said plurality of ferrous tooth components compriseat least two groups of tooth components and wherein said first group oftooth components has a first degree of magnetism and said second groupof tooth components has a second degree of magnetism distinguishablefrom said first degree of magnetism.
 14. A turbine engine shaftcomprising: a shaft body defining an axis; and at least one ferroustooth component including a base portion contacting an inner surface ofthe shaft, a load bearing portion extending radially outward from saidbase portion, relative to the shaft, and a tooth portion extendingradially outward from said load bearing portion, relative to the shaft.